Absorbent article having a pocket cuff

ABSTRACT

A disposable diaper having a waist pocket cuff is disclosed. The pocket cuff has an open edge having an apex. The open edge extends between ends joined to the distal edges of barrier cuffs. The open edge is elastically biased to form the open edge apex along the longitudinal centerline of the disposable diaper.

This is a continuation of application Ser. No. 08/302,569, filed on Sep.8, 1994, which is a continuation-in-part of Ser. No. 08/075,205 filed onJun. 10, 1993 now U.S. Pat. No. 5,397,318.

FIELD OF THE INVENTION

The present invention relates to absorbent articles such as disposablediapers, and more particularly, to absorbent articles having a fecalcontainment pocket cuff having an open edge with an apex.

BACKGROUND OF THE INVENTION

The major function of absorbent articles such as disposable diapers andincontinence briefs or undergarments is to absorb and contain bodyexudates. Such articles are thus intended to prevent body exudates fromsoiling, wetting, or otherwise contaminating clothing or other articles,such as bedding, that come in contact with the wearer. The most commonmode of failure for such products occurs when body exudates leak out ofthe gaps between the article and the wearer's leg or waist. Fecalmaterial that is not absorbed by the absorbent article can work its waypast the gaps in the article in the legs or waist of the wearer.

Contemporary disposable diapers have a topsheet, a backsheet, anabsorbent core, and elasticized leg or gasket cuffs generally formedfrom an elastic member enclosed between portions of the topsheet andbacksheet which extend beyond the edges of the absorbent core. Theseelasticized leg or gasket cuffs present a barrier between the edge ofthe diaper and the wearer's contacting clothing, and in addition,provide a gasketing action about the legs of the wearer to maintain aseal about the leg and minimize gapping.

Disposable diapers may also be provided with barrier cuffs which inhibitfecal material or gushes of urine or liquids from soiling the wearer'sclothing. The barrier cuffs restrain the free flow of this material tohold such material within the diaper. U.S. Pat. No. 4,743,246 issued May10, 1988, to Lawson discloses an absorbent article having gasket andbarrier cuffs.

Disposable diapers having an opening formed in a topsheet are disclosedin the following references: GB Application 2,265,550A published Oct. 6,1993 in the name of Tanji et al.; U.S. Pat. No. 5,176,672 issued Jan. 5,1993 to Bruemmer et al.; U.S. Pat. No. 5,304,159 issued Apr. 19, 1994 toTanji et al.; and U.S. Pat. No. 5,304,160 issued Apr. 19, 1994 to Igaueet al.

Disposable diapers may also have pockets or waistcaps for reducing theleakage of body exudates from the diaper waist region. Examples of suchdiapers are disclosed in U.S. Pat. No. 4,738,677 issued Apr. 19, 1988,to Foreman, and U.S. Pat. No. 5,026,364 issued Jun. 25, 1991, toRobertson.

Despite the effectiveness of such pockets in containing waste material,it has been found that liquid and solid material can leak past thepocket and soil the wearer's clothing, under certain conditions. Forinstance, forces exerted on the pocket when the diaper is worn may causethe pocket to be pressed against the diaper topsheet, so that the pocketis not open to receive fecal matter. Moreover, the shape andconstruction of the pocket may promote gaps between the pocket cuff andthe wearer's buttocks, thereby providing a leakage path for fecal matterin the absorbent article waist region.

Therefore, it is an object of the present invention to provide anabsorbent article which has improved containment characteristics.

It is an additional object of the present invention to provide anabsorbent article having a pocket cuff which acts as a restraint againstthe leakage of body exudates from the waist region of an absorbentarticle.

It is also an object of the present invention to provide an absorbentarticle having a pocket cuff with an open edge having an apex.

It is a still further object of the present invention to provide anabsorbent article having a pocket cuff extending intermediate barriercuffs.

These and other objects of the invention will be more readily apparentwhen considered in reference to the following description and when takenin connection with the accompanying drawings.

SUMMARY OF THE INVENTION

In accordance with the present invention, a disposable absorbentarticle, such as a diaper, is provided with a liquid pervious topsheet;a liquid impervious backsheet joined to the topsheet; an absorbent corepositioned intermediate the topsheet and the backsheet; and a pocketcuff overlying portion of the topsheet. The pocket cuff has an open edgewith an apex, the open edge extending between open edge ends. The pocketcuff can also have a closed edge, and side edges extendinglongitudinally rearward from the open edge ends.

The diaper includes a pair of barrier cuffs, each barrier cuffpositioned adjacent a longitudinal edge of the diaper. Spacing meansoperatively associated with each barrier cuff aid in spacing the distaledge of each barrier cuff apart from the topsheet. The open edge of thepocket cuff extends intermediate the barrier leg cuffs and the spacingmeans. The spacing means can comprise elastic members which elasticallygather at least a portion of each side edge of the pocket cuff.

The pocket cuff open edge can be elastically biased to form the openedge apex. In one embodiment the pocket cuff open edge is elasticallyextensible intermediate the apex and each of the pocket cuff open edgeends, and can comprise an elastic element extending intermediate theopen edge ends. A portion of the pocket cuff longitudinally rearward ofthe open edge and substantially aligned with the longitudinal centerlineof the disposable absorbent article can be joined to an underlyingportion of the disposable absorbent article, such as the topsheet, toelastically extend the open edge of the pocket cuff and to position theapex longitudinally rearward of the open edge ends. The closed edge ofthe pocket cuff can include a central closed edge portion and generallyforward extending closed edge portions. The central closed edge portionis substantially aligned with the longitudinal centerline of thedisposable absorbent article and disposed intermediate andlongitudinally rearward of the generally forward extending closed edgeportions. The closed edge can be curved to be convex rearward.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the subject matter which is regarded as formingthe present invention, it is believed that the invention will be betterunderstood from the following descriptions which are taken inconjunction with the accompanying drawings in which like designationsare used to designate substantially identical elements, and in which:

FIG. 1 is a top plan view of a disposable diaper having portionscut-away to reveal underlying structure.

FIG. 2 is a perspective view of the disposable diaper embodiment of FIG.1.

FIG. 3 is a fragmentary sectional view taken along section line 3--3 ofFIG. 1.

FIG. 4 is a fragmentary sectional view taken along section line 4--4 ofFIG. 1.

FIG. 5 is a fragmentary top plan view of the disposable diaperembodiment of FIG. 1 enlarged to show the juncture of the pocket cuffwith an inflected barrier leg cuff.

FIG. 6 is a fragmentary instant sectional view taken along line 6--6 ofFIG. 1.

FIG. 7 is a fragmentary instant sectional view taken along line 7--7 ofFIG. 1.

FIG. 8 is a fragmentary instant sectional view taken along line 8--8 ofFIG. 1.

FIG. 9 is a fragmentary instant sectional view taken along line 9--9 ofFIG. 1.

FIG. 10 is a top plan view of a disposable diaper having a pocket cuffwith a substantially laterally extending open edge.

FIG. 11 is a top plan view of a partially constructed disposable diaperillustrating pocket cuff attachment to the diaper.

FIG. 12 is a top plan view of a partially constructed disposable diaperillustrating formation of an apex on the open edge of the pocket cuffwherein a portion of the pocket cuff substantially aligned with thelongitudinal centerline of the disposable absorbent article is joined toan underlying portion of the disposable absorbent article to elasticallyextend the open edge of the pocket cuff and to position the apexlongitudinally rearward of the open edge ends.

FIG. 13 is a top plan view of the completed disposable diaper of FIG. 12showing the apex formed on the pocket cuff open edge.

FIG. 14 is a fragmentary sectional view of the diaper of FIG. 13 takenalong lines 14--14 in FIG. 13.

DETAILED DESCRIPTION OF THE INVENTION

As used herein, the term "absorbent article" refers to articles whichabsorb and contain body exudates and more specifically refers toarticles which are placed against or in proximity to the body of thewearer to absorb and contain the various exudates discharged from thebody. Absorbent articles are typically differentiated by whether theyare reusable or disposable. The term "disposable absorbent article"refers to articles which are intended to be discarded after a single use(i.e., they are not intended to be laundered or otherwise restored orreused). The absorbent articles of the present invention are preferablydisposable absorbent articles. The absorbent articles may be furtherdefined by whether they are "unitary" such that they do not requireseparate manipulative parts or whether they comprise an element of adiaper system such as a separate holder and liner. The absorbentarticles of the present invention are preferably unitary. As usedherein, the term "diaper" refers to a garment generally worn by infantsand incontinent persons that is worn about the lower torso of thewearer. It should be understood, however, that the present invention isalso applicable to other disposable absorbent articles such asincontinence briefs or undergarments, disposable training pants, diaperholders, sanitary napkins, and the like.

FIG. 1 is a plan view of a diaper 20 with portions of the structurebeing cut away to more clearly show the construction of the diaper 20,and with the portion of the diaper 20 which contacts the wearer facingthe viewer. FIG. 2 is a perspective view of the diaper 20 with theportion of the diaper 20 which contacts the wearer facing the viewer.The diaper 20 shown in FIGS. 1 and 2 has a first front waist region 22,a second rear waist region 24, a crotch region 26 disposed between thefront and rear waist regions 22, 24, and a periphery 28 which is definedby longitudinal edges 30 and front and rear end edges 32. The diaper 20additionally has a lateral centerline 34 and a longitudinal centerline36.

FIG. 3 is a fragmentary sectional view taken along section line 3--3 inFIG. 1. Referring to FIGS. 1, 2 and 3, the diaper 20 comprises a liquidpervious topsheet 38, the liquid receiving surface of the diaper 20being generally defined by the topsheet 38 and being designated 40; aliquid impervious backsheet 42 joined to the topsheet 38; and anabsorbent core 44 positioned intermediate the topsheet 38 and thebacksheet 42. The absorbent core 44 has side edges 46 and front and rearwaist edges 48. The diaper 20 also includes a marginal side flap 49extending laterally outward from each side edge 46 of the absorbent core44 in at least the crotch region 26.

The diaper 20 further includes a pocket cuff 50 overlying a portion ofthe topsheet 38. The pocket cuff 50 has a closed edge 52 which can bejuxtaposed with the rear waist region 24, and an open edge 54 extendingbetween laterally spaced apart open edge ends 55. In the embodimentshown in FIG. 1, the open edge ends 55 are positioned intermediatelateral centerline 34 and the rear end edge 32. The open edge 54 has anapex 157 positioned substantially on the longitudinal centerline 36, andcan include an elastic member 154. The pocket cuff 50 and the topsheet38 together define a fecal containment pocket space 51 therebetween, asshown in FIG. 3.

In the embodiment of FIG. 1, the diaper 20 also includes pocket cuffbiasing means 60 for exerting a longitudinally rearward force componenton the pocket cuff 50. Pocket cuff biasing means 60 shapes the open edge54 and biases the open edge 54 away from the lateral centerline 34 andapart from topsheet 38. The pocket cuff biasing means 60 can also exerta laterally outward force component on the pocket cuff 50."Longitudinally rearward" refers to a direction which is generallyparallel to the longitudinal centerline 36 and which is directed asshown by arrow 18 in FIG. 1. "Laterally outward" refers to a directionwhich is generally parallel to the lateral centerline 34 and which isdirected away from the longitudinal centerline 36 as shown by arrows 19in FIG. 1.

The pocket cuff biasing means 60 can comprise a portion of barrier cuffs62 joined to side flaps 49. The pocket cuff open edge 54 extends betweenopen edge ends 55. Each end 55 is joined to a respective barrier cuff62. In FIG. 1, a portion of each barrier cuff 62 extends longitudinallyrearward and laterally outward from a respective open edge end 55. Aportion of each barrier cuff 62 also extends longitudinally forward froma respective open edge end 55.

The diaper 20 can also include a longitudinally oriented biasing means61, such as an elastic member 161, for exerting a longitudinal forcecomponent on the pocket cuff 50 intermediate the pocket cuff open edgeends 55. A "longitudinally oriented biasing means" refers to a biasingmeans which exerts a force oriented to form an included angle A (FIG. 1)with the longitudinal centerline 36 of no more than 45 degrees.

The diaper 20 preferably includes a "dual tension fastening system" asdisclosed in U.S. Pat. No. 5,151,092, issued to Buell et al. on Sep. 29,1992. A dual tension fastening system can include fastening means 80 forsecuring the diaper on the wearer, such as a pair of tape tab fasteners82 disposed in the rear waist region 24. Suitable fastening means 80include but are not limited to adhesive fasteners and mechanicalfasteners. U.S. Pat. No. 5,151,092 is incorporated herein by referenceto show the construction of such a dual tension fastening system.

In the embodiment shown in FIG. 1, the pocket cuff biasing means 60 canbe operatively associated with the fastening means 80. By "operativelyassociated" it is meant that pocket biasing means 60 and the fasteningmeans 80 work together such that forces used to secure the diaper 20 tothe wearer are transmitted from the fastening means 80 through thepocket cuff biasing means 60 to shape the pocket cuff open edge 54. Theforces transmitted through the pocket cuff biasing means 60 can bias thepocket cuff open edge 54 away from the topsheet 38 and away from thelateral centerline 34.

Examining the individual components of the diaper 20 in more detail,FIG. 1 shows an embodiment of the diaper 20 in which the backsheet 42has length and width dimensions generally larger than those of theabsorbent core 44. The backsheet 42 extends beyond the edges of theabsorbent core 44 to thereby form the periphery 28 of the diaper 20. Theperiphery 28 defines the outer perimeter or, in other words, the edgesof the diaper 20. The periphery 28 comprises the longitudinal edges 30and the end edges 32 in the front and rear waist regions 22 and 24. Asshown in FIG. 1, the topsheet 38 is generally coterminous with thebacksheet 42 along at least the end edges 32 and the longitudinal edges30. U.S. Pat. No. 3,860,003, issued to Buell on Jan. 14, 1975 and abovereferenced U.S. Pat. No. 5,151,092 are incorporated herein by referencefor the purpose of showing such diaper configurations. In an alternativeembodiment, the topsheet 38 may have length or width dimensionsgenerally smaller than those of the backsheet 42.

The diaper 20 has a first waist region 22 and a second waist region 24extending, respectively, from the end edges 32 of the diaper periphery28 toward the lateral centerline 34 of the diaper 20 a distance up toabout 1/3, preferably from about 1/8 to about 1/4, of the length of thediaper 20. The waist regions 22 and 24 generally comprise those portionsof the diaper 20 which, when worn, encircle the waist of the wearer. Thecrotch region 26 is that portion of the diaper 20 positioned between thefirst waist region 22 and the second waist region 24, and comprises thatportion of the diaper 20 which, when worn, is positioned between thelegs of the wearer and covers the lower torso of the wearer.

Referring to FIGS. 1 and 3, the absorbent core 44 is disposed betweenthe topsheet 38 and the backsheet 42. The topsheet 38 and the backsheet42 extend beyond the side edge 46 of the absorbent core 44 to form theside flap 49. Each side flap 49 can include a gasket cuff 104 comprisingone or more elastic strands 105 (three strands shown in FIG. 1)positioned outboard of the barrier cuff 62. U.S. Pat. No. 4,695,278issued to Lawson on Sep. 22, 1987, and above referenced U.S. Pat. No.3,860,003 are incorporated herein by reference to show the constructionof such a gasket cuff 104.

The topsheet 38 and backsheet 42 also can extend beyond the waist edge48 of the absorbent core 44 in front and rear waist regions 22 and 24,as shown in FIGS. 1 and 3. Front and rear waist regions 22 and 24 caninclude a waist region elastic feature 120 for providing lateralexpansion of at least a portion of the front and rear waist regions 22and 24. Rear waist region elastic feature 120 can include an elasticizedwaistband 122 extending laterally intermediate a pair of elasticizedside panels 126.

The elasticized waistband 122 can comprise a portion of the topsheet 38,a portion of the backsheet 42, and a bilaminate material 124 positionedbetween the topsheet 38 and the backsheet 42. Referring to FIGS. 1 and4, elasticized side panels 126 can comprise a portion of the topsheet38, a portion of the backsheet 42, and an elastic side panel member 128positioned between the topsheet 38 and the backsheet 42. Abovereferenced U.S. Pat. No. 5,151,092 is incorporated herein by referenceto show the construction of an elastic feature 120, includingelasticized side panels 126 and elasticized waistband 122.Alternatively, the rear waist region elastic feature 120 can comprise anelasticized waistband constructed in accordance with U.S. Pat. No.4,515,595 issued to Kievit et al. on May 7, 1985, which patent isincorporated herein by reference.

FIG. 1 shows the diaper 20 in its flat-out, uncontracted state (i.e.,with all the elastic induced contraction in the barrier cuffs 62, gasketcuffs 104, and waist elastic features 120 pulled out). The elasticmembers 154 and 161 can maintain at least some elastic contraction whenthe diaper is in its flat-out, uncontracted state. FIG. 2 shows thediaper 20 contracted, with at least some elastic induced contraction inthe barrier cuffs 62, the gasket cuffs 104, and waist elastic features120.

The absorbent core 44 may be any means which is generally compressible,conformable, non-irritating to the wearer's skin, and capable ofabsorbing and retaining liquids and certain body exudates. The absorbentcore 44 may be manufactured in a wide variety of sizes and shapesincluding, but not limited to, rectangular, hourglass, asymmetric, andT-shaped. The absorbent core 44 can be manufactured from a wide varietyof liquid absorbent materials commonly used in disposable diapers andother absorbent articles, such as comminuted wood pulp which isgenerally referred to as airfelt.

Examples of other suitable absorbent materials include creped cellulosewadding, absorbent foams, absorbent sponges, super absorbent polymers,absorbent gelling materials, or any equivalent materials or combinationof materials. The total absorbent capacity of the absorbent core 44should, however, be compatible with the design exudate loading in theintended use of the diaper 20. Further, the size and absorbent capacityof the absorbent core 44 may be varied to accommodate wearers rangingfrom infants through adults.

The absorbent core 44 may comprise a layer of absorbent materialcomprising hydrophilic fibers and particles of absorbent gellingmaterial (hydrogel) such as the absorbent structure described in U.S.Pat. No. 4,610,678 issued to Weisman et al. on Sep. 9, 1986. U.S. Pat.No. 4,673,402 issued to Weisman et al. on Jun. 16, 1987, and U.S. Pat.No. 4,888,321 issued Dec. 19, 1989, to Angstadt also describe absorbentstructures that are useful in the present invention. The absorbent core44 can be the commercially successful absorbent member described in U.S.Pat. No. 4,834,735 issued May 30, 1989, to Alemany et al. The four abovementioned patents are incorporated herein by reference for the purposeof showing suitable constructions for absorbent core 44.

The backsheet 42 is positioned adjacent the absorbent core 44 and can besecured thereto by core attachment means (not shown) such as those wellknown in the art. For example, the backsheet 42 may be secured to theabsorbent core 44 by a uniform continuous layer of adhesive, a patternedlayer of adhesive, or an array of separate lines or spots of adhesive.Adhesives which have been found to be satisfactory are manufactured byCentury Adhesives, Inc. of Columbus, Ohio and marketed under the tradename Century 5227; and by H. B. Fuller Company of St. Paul, Minn. andmarketed as HL-1258. The core attachment means can comprise an openpattern network of filaments of adhesive as is shown in U.S. Pat. No.4,573,986 issued to Minetola et al. on Mar. 4, 1986, and which isincorporated herein by reference. An exemplary attachment means of anopen pattern network of filaments comprises several lines of adhesivefilaments swirled into a spiral pattern such as is illustrated in U.S.Pat. No. 3,911,173 issued to Sprague, Jr. on Oct. 7, 1975; U.S. Pat. No.4,785,996 issued to Ziecker, et al. on Nov. 22, 1978; and U.S. Pat. No.4,842,666 issued to Werenicz on Jun. 27, 1989. Each of these patents areincorporated herein by reference for the purpose of showing suitableattachment means.

The backsheet 42 is impervious to liquids and is preferably manufacturedfrom a thin plastic film, although other flexible liquid imperviousmaterials may also be used. The term "flexible" refers to materialswhich are compliant and which will readily conform to the contours ofthe human body. The backsheet 42 prevents the exudates absorbed andcontained in the absorbent core 44 from wetting articles which contactthe diaper 20 such as bedsheets and undergarments. The backsheet 42 maycomprise a woven or nonwoven material, polymer films such asthermoplastic films of polyethylene or polypropylene, or compositematerials such as film coated nonwoven material. Preferably, thebacksheet 42 is a thermoplastic film having a thickness of from about0.012 mm (0.5 mil) to about 0.051 cm (2.0 mils).

At least a portion of the backsheet 42 can be subjected to mechanicalstretching to form elasticized side panels 126 and to pre-strain aportion of the backsheet coinciding with waist region elastic feature120, as is more fully described in above referenced U.S. Pat. No.5,151,092. Preferred polymer films for use as the backsheet 42 contain ahigh content of linear low density polyethylene.

Suitable materials for the backsheet include blends comprised of about45-90% linear low density polyethylene and about 10-55% polypropylene.Exemplary films for use as the backsheet 42 of the present invention aremanufactured by Tredegar Industries Inc. of Terre Haute, Ind. under thedesignation RR8220 blend for blown films and RR5475 blend for castfilms.

The backsheet 42 can be embossed, such as to a caliper of about 0.127 mm(5.5 mils), and/or matte finished to provide a more clothlikeappearance. Further, the backsheet 42 may permit vapors to escape fromthe absorbent core 44 while still preventing exudates from passingthrough the backsheet 42.

The size of the backsheet 42 is dictated by the size of the absorbentcore 44 and the exact diaper design selected. In one embodiment, thebacksheet 42 has a modified hourglass shape extending beyond theabsorbent core 44 a minimum distance of at least about 1.3 cm to about2.5 cm (about 0.5 to about 1.0 inch) around the entire diaper periphery28.

The topsheet 38 is joined to the absorbent core 44 and the backsheet 42by attachments means (not shown) such as those well known in the art.Suitable attachment means are described above with respect to joiningthe backsheet 42 to the absorbent core 44. As used herein, the term"joined" encompasses configurations whereby an element is directlysecured to the other element by affixing the element directly to theother element, as well as configurations whereby the element isindirectly secured to the other element by affixing the element tointermediate members which in turn are affixed to the other element. Inone embodiment the topsheet 38 and the backsheet 42 are joined directlyto each other in at least a portion of the periphery 28 of the diaper20, and are indirectly joined together by directly joining the topsheet38 and the backsheet 42 to the absorbent core 44.

The topsheet 38 is compliant, soft feeling, and non-irritating to thewearer's skin. Further, the topsheet 38 is liquid pervious permittingliquids to readily penetrate through its thickness. A suitable topsheetmay be manufactured from a wide range of materials, such as porousfoams, reticulated foams, apertured plastic film, natural fibers (e.g.,wood or cotton fibers), synthetic fibers (e.g., polyester orpolypropylene fibers) or from a combination of natural and syntheticfibers. Preferably, it is made of a hydrophobic material to isolate thewearer's skin from liquids in the absorbent core 44. At least a portionof topsheet 38 may be subjected to mechanical stretching to form theelasticized side panels 126, as is disclosed in above referenced U.S.Pat. No. 5,151,092.

There are a number of manufacturing techniques which may be used tomanufacture the topsheet 38. For example, the topsheet 38 may be anonwoven web of fibers. When the top sheet 38 comprises a nonwoven web,the web may be spunbonded, carded, wet-laid, meltblown, hydroentangled,or the like. A suitable topsheet 38 can be carded and thermally bondedby means well known to those skilled in the fabric art. A suitabletopsheet 38 comprises staple length polypropylene fibers having a lengthof at least about 15.9 mm (0.625 inch) and has a basis weight from about18 to about 25 grams per square meter. A suitable topsheet material ismanufactured by Veratec, Inc., a Division of International PaperCompany, of Walpole, Mass., under the designation P-8.

Referring to FIGS. 1, 4, and 9, each barrier cuff 62 has a proximal edge64, a distal edge 66, a first barrier cuff end 72 positioned in thefront waist region 22, and a second barrier cuff end 74 positioned inthe rear waist region 24. The barrier cuff 62 further comprises aspacing means 76 operatively associated with the barrier cuff 62 forspacing the distal edge 66 apart from the topsheet 38. The spacing means76 can comprise one or more elastic members 77, as shown in FIG. 9.Barrier cuff 62 can comprise a laminate of a nonwoven material layer 67secured to a liquid impermeable polyethylene film layer 69. Layers 67and 69 can be secured to each other by any method as is known in theart.

The barrier cuff 62 is preferably formed by joining portions of aseparate barrier cuff member to the diaper 20 adjacent the longitudinaledge 30. The proximal edge 64 of the barrier cuff 62 is formed byjoining a segment of the barrier cuff member to the diaper 20 by a sealmeans (not shown) so as to form a seal along the proximal edge 64, andto present a barrier to liquids wicking past the barrier cuffs 62. Theseal means can comprise any of several securement means known in the artsuch as ultrasonic bonds, heat/pressure bonds, or seals using a varietyof bonding patterns, or adhesives or glues. A suitable seal meanscomprising one or more lines of hot melt adhesive is disclosed in U.S.Pat. No. 5,087,255 issued Feb. 11, 1992, to Sims, which patent isincorporated herein by reference.

The proximal edge 64 is preferably joined to the side flap 49 to bepositioned laterally inward of the gasket cuff 104 in the crotch region26. The proximal edge 64 can be joined to the topsheet 38.Alternatively, if the topsheet 38 does not extend laterally outward ofthe barrier cuff 62, the proximal edge 64 can be joined to the backsheet42.

As shown in FIG. 9, the distal edge 66 is formed by folding the barriercuff 62 back upon itself and securing it to another segment of thebarrier cuff 62 to form a hem. The spacing means 76, preferably thethree elastic members 77 shown in FIG. 9, is enclosed in the hem.

The elastic members 77 are operatively associated with the barrier cuff62 by an attachment means (not shown). The attachment means preferablysecures the elastic members 77 to the barrier cuff 62 in an elasticallycontractible condition. The elastic members 77 contract or gather thedistal edge 66 of the barrier cuff 62, so that the distal edge 66 isspaced away from the topsheet 38, as shown in FIGS. 6-9.

The elastic members 77 can be made from a number of suitable materialsincluding elastomeric films, polyurethane films, Lycra, elastomericfoams, and formed elastic scrim. A suitable elastic member 77 includesan elastic strand having a cross section of 0.18 mm by 1.5 mm and madefrom natural rubber, such as is available from Easthampton RubberCompany of Stewart, Va. as L-1900 Rubber Compound. Other suitableelastic members include elastic tapes such as those sold by the FulflexCompany of Middletown, R.I. under the name Fulflex 9411. A suitableelastic attachment means for securing elastic members 77 to barrier cuff62 can include an adhesive, such as a hot melt adhesive marketed byFindley Adhesives of Elmgrove, Wis. as Findley Adhesive 581.

A more detailed description of the manner in which elastic members 77can be secured to barrier cuffs 62 in an elastically contractible mannercan be found in the following patents which are incorporated herein byreference: U.S. Pat. No. 3,860,003 issued to Buell on Jan. 26, 1974;U.S. Pat. No. 4,081,301 issued to Buell on Mar. 28, 1978; and U.S. Pat.No. 4,253,461 issued to Strickland et al. on Mar. 3, 1981.

The distal edge 66 is secured to the diaper 20 at the first and secondbarrier cuff ends 72 and 74 in the front and rear waist regions 22 and24, respectively. The distal edge 66 can be secured to an underlyingelement of the diaper 20, such as the topsheet 38. Alternatively, thedistal edge 66 can be secured to the backsheet 42 if the topsheet 38does not extend fully into the front or rear waist regions 22 and 24.The distal edge 66 can be secured to the underlying element by any ofseveral securement means known in the art such as ultrasonic bonds,heat/pressure bonds, or seals using a variety of bonding patterns, oradhesives or glues. A suitable securement means comprising one or morebeads of hot melt adhesive is disclosed in above referenced U.S. Pat.No. 5,087,255, which patent is incorporated herein by reference.

In the embodiment of FIGS. 1 and 2, the barrier cuff 62 is secured atthe first and second barrier cuff ends 72 and 74 so as to have aninflected configuration. By an "inflected" configuration it is meantthat the distal edge 66 is secured to extend laterally inward of theproximal edge 64 at the first barrier cuff end 72, and that the distaledge 66 is secured to extend laterally outward of the proximal edge 64at the second barrier cuff end 74. The barrier cuff 62 is therebyturned, or "flipped out" as the barrier cuff 62 extends from the frontwaist region 22 to the rear waist region 24. An example of an inflectedbarrier cuff is disclosed in above referenced U.S. Pat. No. 5,087,255,which patent is incorporated herein by reference for the purpose ofshowing an inflected barrier leg cuff construction. In an alternativeembodiment described below, the barrier cuffs 62 can have anon-inflected configuration.

The distal edge 66 is preferably not directly secured to underlyingelements of the diaper 20, such as the topsheet 38 or backsheet 42, inthe crotch region 26. The distal edge 66 can therefore be spaced awayfrom the liquid-receiving surface 40 of the topsheet 38 by the elasticgathering action of the elastic members 77. However, the distal edge 66can be joined to the pocket cuff 50 in the crotch region 26, as will bedescribed in more detail below.

The pocket cuff 50 preferably comprises a material that is compliant,soft, and non-irritating to the wearer's skin. The pocket cuff 50 can beformed from a material that is liquid pervious or liquid impervious. Asuitable pocket cuff 50 may be made from a wide range of materials, suchas apertured plastic films, or woven or nonwoven webs of natural fibers(e.g., wood or cotton fibers) or synthetic fibers (e.g., polyesterpolypropylene, or rayon fibers), or composites of polyolefinic films andnonwovens. Optionally, the pocket cuff 50 may formed from an elastomericweb of material. The pocket cuff 50 can be hydrophobic to isolate thewearer's skin from liquids contained in the pocket space 51 formedbetween the topsheet 38 and the pocket cuff 50. A number of techniquesmay be used to manufacture the pocket cuff 50. For example, the pocket50 may be a nonwoven web of fibers spunbonded, carded, wet laid,meltblown, hydroentangled, or the like. A suitable pocket cuff 50comprises a web of staple length polypropylene fibers. Suitablematerials from which the pocket cuff 50 can be made are manufactured byVeratec, Inc., a Division of International Paper Company, of Walpole,Mass., under the designations P-8, P-9, or P-11.

Referring to FIGS. 1 and 5, the open edge 54 of pocket cuff 50 can beelastically extensible, and can comprise an elastic member 154 whichextends intermediate pocket cuff open edge ends 55. In the embodimentshown in FIGS. 1 and 5, the pocket cuff 50 preferably also comprises alongitudinally oriented biasing means 61. The longitudinally orientedbiasing means 61 can comprise an elastic member 161 extendingintermediate the forward edge 54 and closed edge 52 of pocket cuff 50.The elastic member 161 is preferably substantially aligned withlongitudinal centerline 36 and is preferably equidistantly spaced fromthe open edge ends 55.

Elastic members 154 and 161 can comprise one or more elastic elementsand can comprise a wide variety of materials as are well known in theart including natural or synthetic rubber, elastomeric films, elastictapes, polyurethane films, Lycra, elastomeric foams, and formed elasticscrim. Generally, materials used to form the elastic members 77 can alsobe used to form elastic members 154 and 161. One suitable material forforming elastic members 154 and 161 comprises elastic strands having across-section of 0.18 mm by 1.5 mm and made from natural rubber asavailable from Easthampton Rubber Company of Stewart, Va. under the nameL-1900 Rubber Compound. Another suitable material for forming elasticmembers 154 and 161 comprises a double sided adhesive elastic film suchas Findley Film No. 198-338 having a thickness of about 0.25 mm and awidth of about 12.7 mm available from Findley Adhesives of Elmgrove,Wis. Another suitable material for forming members 154 and 161 isFulflex Ultraflex synthetic rubber manufactured by the Fulflex Companyas Spec. No. 65325, 9EX29, 0.007×5/64.

The elastic member 154 is preferably secured to the pocket cuff 50 in anelastically contractible manner so that in an unrestrained configurationthe elastic member 154 gathers the open edge 54. The elastic element 161is also preferably secured to the pocket cuff 50 in an elasticallycontractible manner so that the elastic member 161 exerts alongitudinally rearward force component on the open edge 54. Thelongitudinal rearward force component gathers the pocket cuff 50 tospace the open edge 54 apart from the top sheet 38.

In the embodiment shown in FIGS. 1 and 5, the longitudinal rearwardforce component provided by the elastic member 161 also preferablyshapes the open edge 54 to form an apex 157 substantially positioned onlongitudinal centerline 36 to be generally aligned with the wearer'sgluteal groove, and spaced approximately equidistant from open edge ends55. The apex 157 is disposed longitudinally rearward of an imaginarylateral line passing through the open edge ends 55. The portions of theopen edge 54 extending from each open edge end 55 to the apex 157 aregathered by elastic member 154. The open edge 54 can thereby form a sealor gasket with the wearer's buttocks on each side of the wearer'sgluteal groove. FIG. 10 shows a disposable diaper having a pocket cuffopen edge 54 which does not include an apex 157.

The apex 157 forms one vertex of an imaginary triangle. The imaginarytriangle has vertices at apex 157 and at open edge ends 55. The openedge 54 comprises two sides of the imaginary triangle, and forms anincluded angle B (FIG. 5) at apex 157.

The open edge 54 can also be shaped to extend longitudinally rearward ofthe open edge ends 55 by varying the stiffness of the elastic element154 as a function of position along open edge 54. A portion of the openedge 54 can be curved to extend rearward of the open edge ends 55 if thestiffness, or spring rate, of the elastic member 154 has a maximum valueat the center of the open edge 54, and a lower stiffness value adjacentthe open edge ends 55. Such a stiffness variation can be obtained in anumber of ways. For example, the elastic member 154 can comprise twoelastic elements centered on the open edge 54 and having differentlengths.

Referring to FIG. 3, the pocket cuff 50 can be formed from a sheet ofmaterial, such as a nonwoven, having two sheet halves 174 and 176. Theelastic element 154 can be secured along a length of the sheet half 174adjacent to sheet half 176 in an elastically contractible manner, suchas by stretching the elastic member 154 and securing the stretchedelastic member 154 to the sheet half 174 with an adhesive. The elasticmember 161 can be secured along the width of sheet half 174 in anelastically contractible manner to bisect the sheet half 174. Abovereferenced U.S. Pat. Nos. 3,860,003 and 4,081,301 are incorporatedherein by reference to show an elastic member secured to a diapercomponent in an elastically contractible manner.

The elastic member 154 can comprise two pieces of the above-referencedFindley Film. A first piece of film can have a free length of about 2.54cm (inch) and can be stretched to a length of about 9.5 cm (3.75 inches)and applied to the center portion of the length of sheet half 174. Thesecond piece of film can have a free length of about 9.5 cm (3.75inches) and be stretched to a length of about 58 cm (23 inches) andapplied to the length of the sheet half 174 to overlie the first pieceof film. The two pieces of film comprising elastic member 154 contractthe length of the sheet half 174 from a free length of about 61 cm (24inches) to a contracted length of about 15.2 cm (6.0 inches).

The elastic member 161 can comprise a piece of the above-referencedFindley Film having a free length of about 1.9 cm (0.75 inch). Theelastic member 161 is stretched to a length of about 7.6 cm (3 inches)and applied to the width of the sheet half 174 to contract the widthfrom a free width of about 9.5 cm (3.75 inches) to a contracted width ofabout 5.1 cm (2.0 inches).

After securing the elastic members 154 and 161 to sheet half 174, sheethalf 176 can be folded along a crease 178 (FIG. 3) to overlie sheet half174 and the elastic members 154 and 161. Sheet half 176 can then besecured to sheet half 174 in any of several ways known in the art, suchas by ultrasonic bonding, heat/pressure sealing, or by bonding the sheethalves 174 and 176 using adhesives or glues, such as an adhesivemanufactured by the H.B. Fuller Company of St. Paul. Minn. under thename HL-1258, or a double sided adhesive tape such as 3M Tape No. 1524available from The 3M Company of St. Paul, Minn. The resulting pocketcuff 50 comprises two layers formed by halves 176 and 174. However, twolayers are not necessary to the operation of the pocket cuff 50, and asuitable pocket cuff 50 can be formed having just one layer, or havingmore than two layers.

The pocket cuff 50 formed in the manner described above is joined to anunderlying element of diaper 20 along closed edge 52 to prevent leakageof body exudates past the rear waist region 24. The pocket cuff can bejoined to topsheet 38 along closed edge 52, as shown in FIGS. 1 and 2.Alternatively, pocket cuff 50 can be joined to backsheet 42 along closededge 52 if topsheet 38 does not extend fully into the rear waist region24.

The pocket cuff 50 can be joined to an underlying element of diaper 20along the closed edge 52 in any of several ways which are well known inthe art. The pocket cuff 50 is preferably joined in a liquid tightrelationship to the underlying element of diaper 20 along closed edge 52such that body exudates are prevented from leaking between pocket cuff50 and the underlying element of the diaper 20. For example, the pocketcuff 50 can be joined to the topsheet 38 with ultrasonic bonding,pressure/heat sealing, or with a continuous layer of an adhesive orglue, such as the HL-1258 adhesive or the 3M Tape No. 1524 referencedabove.

The closed edge 52 can have a generally laterally oriented portion 180extending between generally forward extending portions 182, as shown inFIG. 2. Closed edge 52 preferably extends rearward of the core edge 48associated with rear waist region 24. Closed edge 52 also preferablyextends laterally outward of core edges 46. The laterally extendingportion 180 of closed edge 52 is spaced forward of end edge 32 in 35rear waist region 24, and the forward extending portions 182 of closededge 52 are spaced laterally inward from barrier cuffs 62 in the rearwaist region 24, as shown in FIG. 2. Alternatively, the laterallyextending portion 180 could coincide with the end edge 32 and theforward extending portions 182 could coincide with the proximal edges 64of the barrier cuffs 62 in the rear waist region 24.

The open edge 54 or the pocket cuff 50 extends between the laterallyspaced apart open edge ends 55. The open edge ends 55 are joined to thebarrier cuffs 62 at a pair of laterally spaced apart junctures 155, asshown in FIGS. 1, 2, and 5. Each juncture 155 is positioned intermediatethe first end 72 and the second end 74 of a barrier cuff 62.

FIG. 1 shows inflected barrier cuffs 62 having the distal edge 66extending laterally inward of the proximal edge 64 at the first barriercuff end 72, and the distal edge 66 extending laterally outward of theproximal edge 64 at the second barrier cuff end 74. FIGS. 6-9 illustratethe inflected nature of the barrier cuff 62. FIG. 6 is an instantsectional view taken along line 6--6 in FIG. 1, rearward of juncture155. FIG. 6 shows the barrier cuff 62 "flipped out" with distal edge 66of the barrier cuff 62 extending laterally outward of the proximal edge64. FIGS. 8 and 9 are instant sectional views taken forward of thejuncture 155. FIGS. 8 and 9 show the barrier cuff 62 "flipped in" in thecrotch region 26, with the distal edge 66 of the barrier cuff 62extending laterally inward of the proximal edge 64. Elastic members 77space the distal edge 66 of the barrier cuff 62 above topsheet 38 toform channel 177. Channel 177 and the barrier cuff 62 contain bodyexudates and prevent leakage of the exudates from between the wearer'sleg and the diaper 20.

Referring to FIGS. 1 and 7, each open edge end 55 can be joined to thedistal edge 66 of a barrier cuff 62. In one preferred embodiment theelastic member 154 extends between the open edge ends 55. Each open edgeend 55 is joined to a distal edge 66, such that the elastic member 154is juxtaposed with the elastic members 77 operatively associated withthe distal edges 66 of the barrier cuffs 62. The elastic members 77 canextend longitudinally rearward and laterally outward from each juncture155 to underlie a portion of a tape tab fastener 82.

The open edge end 55 can be joined to the distal edge 66 of the barriercuff 62 in any of several ways known in the art, such as by ultrasonicbonding, heat/pressure sealing, or by bonding using adhesives or glues,such as the HL-1258 adhesive or the 3M Tape No. 1524.

Referring to FIG. 7, a channel 171 can be formed between the closed edge52 of the pocket cuff 50 and the proximal edge 64 of the barrier cuff 62if the pocket cuff 50 is only joined locally to the distal edge 66 ofthe barrier cuff 62. Referring to FIG. 8, the pocket cuff 50 can becontinuously joined along the full width W of barrier cuff 62 in orderto close channel 171, thereby preventing longitudinal leakage of bodyexudates between the barrier cuff 62 and the pocket cuff 50.

The barrier cuff 62 is in a generally upright position at juncture 155,as shown in FIG. 7. The juncture 155 provides a transition, orinflection point, between the flipped out portion of barrier cuff 62 andthe flipped in portion of the barrier cuff 62. The juncture 155 and theassociated open edge end 55 also comprise the intersection of agenerally Y-shaped load carrying structure.

Referring to FIG. 5, this Y-shaped load carrying structure comprises theopen edge 54 of the pocket cuff 50 and also comprises the barrier cuff62. A first branch 201 of the Y-shaped structure comprises a portion ofbarrier cuff 62 extending laterally outward and longitudinally rearwardfrom an open edge end 55 to a tape tab fastener 82. This first branch201 can include at least a portion of the distal edge 66 and elasticmembers 77.

The second branch 202 of the Y-shaped structure comprises a portion ofthe barrier cuff 62 extending longitudinally forward of open edge end55. The second branch 202 can also extend laterally inward or laterallyoutward from the open edge 55. The second branch 202 can include atleast a portion of the distal edge 66 and elastic members 77. In thepreferred embodiment a single, continuous barrier cuff 62 comprises thefirst and second branches. However, in alternative embodiments the firstand second branches can each comprise a separate barrier cuff structure.

The third branch 203 of the Y-shaped structure comprises a portion ofthe open edge 54. This third branch 203 can include a portion of theelastic element 154. In a preferred embodiment including alongitudinally oriented elastic member 161, the third branch 203 of theY-shaped structure comprises portions of the open edge 54 and elasticelement 154 which extend laterally inward and longitudinally rearwardfrom an open edge end 55 to the apex 157.

The first branch 201 of the Y-shaped structure exerts a longitudinallyrearward force component and a laterally outward force component on theopen edge end 55. These force components are preferably transmitted fromthe tape tabs 82, shown in FIG. 1, as is discussed in more detail below.The longitudinally rearward force component biases the open edge end 55away from the lateral centerline 34. The laterally outward forcecomponent biases the open edge end 55 away from the longitudinalcenterline 36.

The two force components transmitted by the first branch 201 aid inshaping the open edge 54 of the pocket cuff 50 in the plane of thediaper 20. The plane of the diaper 20 is defined by the longitudinal andlateral centerlines 34 and 36. The two force components can also act tospace the pocket cuff 50 apart from the topsheet 38, and thereby openpocket space 51 to receive body exudates.

The longitudinal force component in the second branch 202 of theY-shaped structure offsets the longitudinal force component transmittedby the first branch 201 (as well as any longitudinal force componentexerted on the open edge end 55 by the third branch 203). The secondbranch 202 of the Y-shaped structure exerts a longitudinally forwardforce which biases the open edge end 55 toward the lateral centerline34. Each open edge end 55 can be viewed as being suspended between twoseries connected longitudinal springs. The elastic members 77 providethe spring compliance. The position of the open edge ends 55 istherefore variable with respect to the diaper end edge 32 in the rearwaist region 24.

As the elastic members 77 in the distal edge 66 of the barrier cuff 62are extended, such as when the diaper 20 is applied to the wearer, theposition of the open edge ends 55 can shift longitudinally. The amountthe elastic members 77 are extended will vary with the size of thewearer of the diaper 20. Therefore, the longitudinal position of theopen edge ends 55 can advantageously vary to accommodate different sizewearers.

The laterally inward force component exerted by the third branch 203 ofthe Y-shaped structure offsets the laterally outward force componentexerted by the first branch 201. In particular, the open edge 54 acts asa structural connection between the two barrier cuffs 62. The lateralforce component exerted by the open edge 54 helps to establish the pointof inflection of the barrier cuffs 62, and helps to prevent the barriercuffs 62 from becoming flipped out forward of the open end edges 55. Itis desirable that the barrier cuffs 62 be maintained in a flipped inconfiguration forward of the open edge ends 55 to prevent leakage pastthe barrier cuffs 62 in the crotch region 26.

In order to establish the correct loading in the Y-shaped structuredescribed above, the open edge ends 55 should be located intermediatethe lateral centerline 34 and the fastening means 80. Preferably, theopen edge ends 55 are positioned rearward of the lateral centerline 34and forward of the forward most portions of the laterally spaced aparttape tabs 82. The open edge ends 55 should also be positioned laterallyinward from the tape tabs 82.

For diaper embodiments fitting babies weighing between about 7.3 and11.3 kg (16.0 and 25.0 lbs.), the open edge ends 55 should be laterallyspaced apart about 8.9 to 11.4 cm (3.5 to 4.5 inches) when the diaperelastic is contracted. The open edge ends 55 should be positionedlongitudinally forward from the diaper rear end edge 32 about 11.4 to14.0 cm (4.5 to 5.5 inches) when the diaper elastic is contracted, andabout 17.8 to 20.3 cm (7.0 to 8.0 inches) when the diaper is in itsflat-out, uncontracted state (i.e., with all the elastic inducedcontraction in the barrier cuffs 62, the gasket cuffs 104, and wainelastic features 120 pulled out). The apex 157 should be positionedlongitudinally forward of the diaper rear end edge 32 about 6.3 to 8.9cm (2.5 to 3.5 inches) when the diaper elastic is contracted, and about10.2 cm (4 inches) when the diaper is in its flat-out, uncontractedstate. The included angle B formed by the open edge 54 at the apex 157can preferably be between 45° and 135°. In one preferred embodiment theincluded angle B is less than 120° when the diaper elastic iscontracted, and is less than 120° when the diaper 20 is in its flat-out,uncontracted state.

The distal edge 66 of each barrier cuff 62 can extend longitudinallyrearward and laterally outward from an open edge end 55 to beoperatively associated with a tape tab 82, shown in FIG. 1. The distaledge 66 can extend longitudinally rearward and laterally outward from anopen edge end 55 to form an included angle A with the longitudinalcenterline 34. This included angle A can be between about 10 to about 60degrees when the diaper 20 is in its uncontracted state, as shown inFIG. 1.

The distal edge 66 of each barrier cuff 62 can be operatively associatedwith a tape tab 82 by directly or indirectly joining the distal edge 66to a portion of the tape tab 82. Referring to FIG. 4, the distal edge 66can be juxtaposed with a portion of the tape tab 82, and can be directlyjoined to a portion of the tape tab 82.

The tape tab 82 comprises a fixed portion 83 joined to the backsheet 42and a tab portion 84 that is grasped by the diaperer when securing thediaper 20 to the wearer. The tape tab 82 also comprises a releaseportion 85 joined to the topsheet 38. The tab portion 84 includes anadhesive layer for attachment to a landing member (not shown) in thefront waist region 22. During manufacture the tab portion 84 is foldedto overlie the release portion 85 to protect the adhesive layer on tabportion 84. The release portion 85 may comprise silicone coated highdensity polyethylene. The release portion 85 allows the tab portion 84to be extended without damaging the adhesive layer or the topsheet 38.U.S. Pat. No. 3,848,594 issued to Buell on Nov. 19, 1974, isincorporated herein by reference for the purpose of showing an exemplarytape tab construction. The tab portion 84 is shown folded in FIG. 4 andis shown extended for grasping in FIG. 2.

In the embodiment shown in FIG. 4, a portion of the release member 85 isjuxtaposed over a portion of the distal edge 66. The release member 85can be adhesively joined to a portion of the distal edge 66. The distaledge 66 can be juxtaposed over, and adhesively joined to, a portion ofthe rear waist region elastic feature 120. In FIG. 4, a portion of thedistal edge 66 is juxtaposed with a portion of the elasticized sidepanel 126. A portion of the elasticized side panel 126, in turn, can bejuxtaposed over, and adhesively joined to, the fixed portion 83 of thetape tab 82. Thus, a portion of the distal edge 66 and the elasticizedside panel 126 are joined together and disposed between the releaseportion 85 and the fixed portion 83 of the tape tab 82.

Without being limited by theory, the distal edge 66 is juxtaposed with aportion of the tape tab 82 to provide a direct load path between thetape tab 82 and the juncture 155. The tape tab 82 is juxtaposed with aportion of the waist region elastic feature 120 to enhance the transferof tape tab loads to the distal edge 66, and thus to juncture 155.

The diaper 20 is applied to the wearer by positioning the rear waistregion 24 under the wearer's back and drawing the remainder of thediaper 20 between the wearer's legs, so that the front waist region 22is positioned across the front of the wearer. The ends of the tape tabs82 are then secured to the landing members (not shown) in the frontwaist region 22.

FIGS. 11-14 illustrate another embodiment of a disposable diaper 20having a pocket cuff 50. FIGS. 11 and 12 illustrate steps in forming thecompleted diaper 20 shown in FIGS. 13 and 14. The diaper 20 shown inFIGS. 13-14 has barrier cuffs 62 which are not inflected, though it willbe understood that the barrier cuffs 62 could be inflected if desired.

The pocket cuff 50 can be formed from a sheet of material, such as theabove mentioned P-8 material. Such a material can have a stiffness intension that varies with direction. The material is preferably orientedsuch that the direction of lowest stiffness of the material is alignedgenerally parallel to the longitudinal centerline 36.

The sheet of pocket cuff material can have a length of about ten inchesand a width of about ten inches. An elastic member 154 having a freelength of about four inches can be joined in an elastically contractiblemanner to extend widthwise along one side of the sheet of materialmidway along the length of the sheet. The elastic member 154 iselongated prior to it being joined to the sheet of pocket cuff material.The elongation of the elastic member 154 can vary with position alongits length. For example, the free, relaxed elastic member 154 can have atotal length of four inches with a one inch center portion, two adjacent1.25 inch side portions, and two 0.25 inch end portions. In oneembodiment, the center portion of the relaxed elastic member 154 can beelongated about 400 percent (to about four inches) prior to being joinedto the sheet of material, the adjacent side portions can be elongatedabout 250 percent prior to being joined to the sheet of material, andthe end portions can remain unelongated upon being joined to the sheetof pocket cuff material. A suitable elastic member 154 comprises FulflexUltraflex synthetic rubber manufactured by the Fulflex Company as Spec.No. 65325, 9EX29, 0.007×5/64. The elastic element 154 can be joined tothe sheet of material adhesively or by other means. A suitable adhesivefor joining the elastic member 154 to the sheet of material is FindleyAdhesive 2031 manufactured by Findley Adhesives.

Once the elastic member 154 is joined to the sheet of pocket cuffmaterial, the sheet of pocket cuff material is folded along a crease 178corresponding to the pocket cuff open edge 54 (FIG. 14) to provide twosheet halves 174 and 176 (FIGS. 11, 12 and 14). The sheet halves 174 and176 can be adhesively bonded together and trimmed to have a lengthparallel to the longitudinal centerline 36 of about four inches and awidth parallel to the lateral centerline 34 of about 9 inches.

Referring to FIG. 11, the folded and trimmed pocket cuff sheet materialcan then be joined to an underlying portion of the disposable absorbentdiaper 20. The folded and trimmed pocket cuff sheet material is joinedto the diaper 20 with the distal edges 66 of the barrier cuffs 62unattached to the underlying diaper structure and positioned laterallyoutward of the proximal edges 64 of the barrier cuffs 62. A laterallyextending attachment means 402 joins an end 302 of the folded pocketsheet material to the topsheet 38 and the barrier cuffs 62. Theattachment means 402 can be positioned about 5 inches longitudinallyforward of the end edge 32 disposed in the rear waist region 24.Longitudinally extending pocket cuff side attachment means 404 areprovided on each barrier cuff 62. The side attachment means 404 extendforward of the laterally extending attachment means 402.

Referring to FIG. 12, the crease 178 corresponding to the open edge 54is brought forward of the end 302 so that pocket cuff side edges 304 canbe joined to the barrier cuffs 62 by the side attachment means 404. Thepocket cuff side edges 304 are joined to the barrier cuffs 62 while theelastic members 77 of the barrier cuffs are extended. When the forcesholding the elastic members 77 in an extended state are released, theelastic members 77 elastically gather the pocket cuff side edges 304, asshown in FIG. 12. Each pocket cuff side edge 304 extends longitudinallyrearward from the open edge 54, as shown in FIG. 12.

Referring to FIGS. 12 and 13, the apex 157 is formed by joining aportion of the pocket cuff 50 substantially aligned with thelongitudinal centerline 36 to an underlying portion of the diaper 20. InFIG. 12, a portion 409 of the pocket cuff 50, including a portion 410substantially aligned with the longitudinal centerline 36 and disposedintermediate the open edge 54 and the end 302, is shown as an arcuatedotted line. The portion 410 of the pocket cuff 50 is displacedlongitudinally rearward of the end 302 and joined to the topsheet 38 byan attachment means 408. Displacing the portion 410 of the pocket cuff50 longitudinally rearward tensions the elastic element 154 and theportions of the elastic members 77 of the barrier cuffs 62 positionedforward of the open edge ends 55, thereby elastically extending the openedge 54 of the pocket cuff and positioning the apex 157 longitudinallyrearward of the open edge ends 55. The pocket cuff open edge 54 isthereby elastically biased in the longitudinal direction by the elasticmember 154 and the elastic members 77 to form the apex 157 (FIG. 13).

The portion 409 of the pocket cuff 50, when joined to the topsheet 38,provides a pocket cuff closed edge 52 (FIG. 13) comprising a central,generally laterally extending closed edge portion 180 disposedintermediate generally forwardly extending closed edge portions 182. Theattachment means 408 can be shaped convex rearward, as shown in FIG. 12,to provide a convex rearward shaped closed edge 52, as shown in FIG. 13.Attachments means 402, 404, and 408 can comprise adhesive or othersuitable attachment means. An example of suitable attachment means 402,404, and 408 is 1/4" double sided tape, No. 1524 manufactured by The 3MCompany.

Once the side edges 304 and the closed edge 52 are formed, the distaledges 66 of the barrier cuffs 62 can be folded laterally inward of theproximal edges 64, as shown in FIG. 13. The distal edges 66 can then beadhesively secured to an underlying diaper structure laterally inward ofthe proximal edges 64 at the first and second barrier cuff ends 72 and74.

In the embodiment shown in FIG. 13, the elastic members 77 in the distaledge 66 of the barrier cuffs 62 extend longitudinally rearward andlongitudinally forward of the open edge ends 55. The open edge 54extends longitudinally rearward and laterally inward of each open edge55 to form an angle C with an adjacent distal edge 66 of a barrier cuff62. The angle C can be between about 10 degrees and about 70 degreeswhen the diaper is in its flatout, uncontracted state. The apex 157 canbe positioned longitudinally forward of the diaper rear end edge 32 fromabout 3 inches to about 5 inches when the diaper is in its flat-out,uncontracted state. The elastic members 77 and the elastic member 154elastically gather the pocket cuff 50 and promote spacing of the openedge 54 from the topsheet 38

While particular embodiment of the present invention have beenillustrated and described, it would be obvious to those skill in the artthat various other changes and modifications can be made withoutdeparting from the spirit and scope of the present invention. It istherefore intended to cover in the appended claims all such changes andmodifications.

What is claimed is:
 1. A disposable absorbent article having a front waist region, a rear waist region longitudinally spaced from the front waist region, a crotch region disposed between the front and rear waist regions, longitudinal edges, end edges, a longitudinal centerline and a lateral centerline, the disposable absorbent article comprising:a liquid pervious topsheet; a liquid impervious backsheet joined to the topsheet; an absorbent core positioned between the topsheet and the backsheet, the absorbent core having side edges and front and rear waist edges; a side flap extending laterally outward from each side edge of the absorbent core; a fastening means for securing the disposable absorbent article on the wearer; a barrier cuff disposed adjacent each longitudinal edge of the disposable absorbent article, each barrier cuff extending longitudinally from a first barrier cuff end in the front waist region to a second barrier cuff end in the rear waist region, and each barrier cuff having a proximal edge and a distal edge, each proximal edge joined to a side flap, each barrier cuff being inflected to have the distal edge extending laterally inward of the proximal edge at the first barrier cuff end and the distal edge extending laterally outward of the proximal edge at the second barrier cuff end; spacing means operatively associated with each barrier cuff for spacing a portion of each barrier cuff distal edge apart from the topsheet; and a pocket cuff positioned intermediate the barrier cuffs and operatively associated with the fastening means, the pocket cuff having an open edge extending intermediate the inflected barrier cuffs.
 2. The disposable absorbent article of claim 1 wherein the open edge end extends intermediate laterally spaced apart open edge ends, and wherein each open edge end is joined to a barrier cuff at a juncture positioned intermediate the first and second barrier cuff ends.
 3. The disposable absorbent article of claim 2 wherein the open edge has an apex positioned intermediate the open edge ends, the apex disposed longitudinally rearward of a line passing through the open edge ends.
 4. The disposable absorbent article of claim 3 wherein the apex is positioned substantially on the longitudinal centerline of the disposable absorbent article.
 5. The disposable absorbent article of claim 3 wherein the apex is positioned substantially equidistant from the open edge ends.
 6. The disposable absorbent article recited in claim 1 wherein the pocket cuff is elastically extensible intermediate the pocket cuff open edge ends.
 7. The disposable absorbent article recited in claim 6 wherein the pocket cuff open edge is elastically extensible intermediate the apex and each of the pocket cuff open edge ends.
 8. The disposable absorbent article recited in claim 7 wherein the pocket cuff open edge comprises an elastic member extending intermediate the open edge ends.
 9. The disposable absorbent article recited in claim 3 wherein a portion of the pocket cuff is joined to an underlying portion of the disposable absorbent article to elastically extend the open edge of the pocket cuff and to position the apex longitudinally rearward of the open edge ends.
 10. The disposable absorbent article recited in claim 3 wherein a distal edge of a barrier cuff extends longitudinally rearward and laterally outward from each juncture.
 11. The disposable absorbent article recited in claim 10 wherein said fastening means comprises a pair of fastening members, and wherein the distal edge of a barrier cuff extends intermediate a juncture and a fastening member.
 12. The disposable absorbent article recited in claim 3 comprising an elastic member for biasing each pocket cuff open edge end longitudinally rearward and laterally outward.
 13. The disposable absorbent article recited in claim 12 further comprising an elastic member for biasing each pocket cuff open edge end longitudinally rearward and laterally inward.
 14. The disposable absorbent article recited in claim 13 further comprising an elastic member for biasing the pocket cuff open edge apex longitudinally rearward. 